Devices and systems for measuring the state of a valve, and related methods

ABSTRACT

A device for measuring a state of a valve may include a housing configured to connect to a handle of a valve or a body of a valve, a sensor supported on one of the housing or the valve stem, and an indicator detectable by the sensor. The indicator may be configured to move relative to the sensor in response to movement of a valve stem or valve handle during opening and closing of the valve. The sensor may be configured to detect a position of the indicator to determine a state of the valve. Related systems and methods are also described.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 63/201,412, filed Apr. 28, 2021, and entitled “DEVICES AND SYSTEMS FOR MEASURING THE STATE OF A VALVE, AND RELATED METHODS,” the disclosure of which is hereby incorporated herein in its entirety by this reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with government support under Contract Number DE-AC07-05-ID14517 awarded by the United States Department of Energy. The government has certain rights in the invention.

TECHNICAL FIELD

This disclosure relates devices and systems for measuring the state of the valve, and related methods. This disclosure further relates to systems, devices, and methods for measuring the state of a valve, and methods of forming one or more components of such devices. The devices and systems as described herein may enable more accurate measurement of valve states, verification of valve states, retrofitting of existing valves, and easy deployment on, and detachment from, valves.

BACKGROUND

Valves may be used in a variety of applications to control the flow of fluids through piping systems. There are several different types of valves used for controlling flow such as ball valves, gate valves, butterfly valves, needle valves, globe valves, check valves, and the like. Depending on the type and design, valves may be automatically or manually manipulated. For example, valves may include actuators or manual devices such as handles, hand-wheels, and levers that can be manipulated to control a valve state (e.g., whether a valve is fully opened, fully closed, or in some intermediate state).

Many industrial facilities utilize a wide variety of manual valves that are regularly manipulated by skilled workers. For example, valves may be manipulated to confirm calibration or to change flowrates in order to achieve desired performance and operating margins.

BRIEF SUMMARY

Embodiments of the present disclosure include devices and systems for measuring the state of the valve, and related methods. A device for measuring a state of a valve comprises a housing configured to be affixed to a handle of a valve, a sensor supported on the housing, and an indicator detectable by the sensor. The indicator is configured to move relative to the sensor in response to movement of a valve stem of the valve during opening and closing of the valve. The sensor is configured to detect a position of the indicator to determine a state of the valve.

Additional embodiments of the present disclosure include a system for measuring a state of a valve. A system for measuring a state of a valve comprises a valve and a sensor device. The valve comprises a valve body, a handle operable to open and close the valve, and a valve stem movable relative to the valve body during opening and closing of the valve. The sensor device comprises a housing affixed to the handle of the valve, a sensor supported on one of the housing or the valve stem, and an indicator detectable by the sensor and supported on the other of the housing or the valve stem. The indicator is configured to relative to the sensor in response to movement of the valve stem during opening and closing of the valve. The sensor is configured to detect a position of the indicator to determine a state of the valve.

Additional embodiments of the present disclosure include a method of forming a device housing for a valve. The method comprises determining at least some dimensions of a valve handle and a valve stem of a valve. The method additionally comprises sequentially placing a material at targeted locations based on the at least some dimensions of the valve stem. The method further comprises affixing the material in place to form a housing configured to receive the valve stem at least partially therein. The method comprises sequentially placing additional material at targeted locations based on the at least some dimensions of the valve handle. The method additionally comprises affixing the additional material in place to form one or more clips secured to the housing and configured to removably connect to the valve handle.

BRIEF DESCRIPTION OF THE DRAWINGS

While this disclosure concludes with claims particularly pointing out and distinctly claiming specific embodiments, various features and advantages of embodiments within the scope of this disclosure may be more readily ascertained from the following description when read in conjunction with the accompanying drawings. In the drawings:

FIG. 1 is a partial cutaway perspective view of an embodiment of a system that includes a device for measuring a state of a valve in accordance with this disclosure;

FIG. 2 is an enlarged perspective view of the device of FIG. 1 .

FIG. 3 is an enlarged perspective view of a housing of the device of FIG. 2 .

FIG. 4 is an enlarged perspective view of one or more clips of the housing of FIG. 3 .

FIG. 5 is a perspective view of another embodiment of a device for measuring a state of a valve, in accordance with this disclosure.

FIG. 6 is a flow chart showing an illustrative method for measuring a valve state, in accordance with embodiments of this disclosure.

FIG. 7 is a flow chart showing an illustrative method for additively manufacturing a housing of a device for measuring a valve state, in accordance with embodiments of this disclosure.

DETAILED DESCRIPTION

The illustrations presented in this disclosure are not necessarily meant to be actual views of any particular device for measuring the state of a valve, or component thereof, but are merely idealized representations employed to describe illustrative embodiments.

Oil and gas facilities, water treatment plants, power plants, chemical processing facilities, biotech, or pharmaceutical production facilities, and other industrial facilities are heavily regulated and utilize a variety of manual valves. As a non-limiting example, nuclear power plants often utilize valves that must be manually manipulated because of the stringent requirements set forth by the Nuclear Regulatory Commission (NRC).

Relying on personnel to manually manipulate valves presents a variety of concerns such as human error, safety, and regulatory compliance. Additionally, manipulating valves often includes concurrent or independent verification of the performed action, whether closing, opening, adjusting, or calibrating the valves. One issue is that it may be difficult to determine the state of a valve from the location of an actuator, handle, hand-wheel, or lever of the valve. Another issue is that certain operating conditions, such as vibration, may cause unintended adjustments to the valves. Therefore a need exists for an improved device for measuring the state of a valve.

Disclosed embodiments relate generally to devices for measuring the state of a valve (e.g., whether a valve is fully opened, fully closed, or somewhere in between fully opened and fully closed) through which a fluid may flow. More specifically, disclosed are embodiments of the devices for measuring the state of the valve (e.g., a rising-stem valve, a rising-handle valve). The device for measuring the state of the valve may include a housing configured to be affixed to a handle of the valve and a sensor supported on the housing. The device may additionally include an indicator detectable by the sensor. The indicator may be configured to move relative to the sensor in response to movement of, for example, a valve stem or a valve handle during opening and closing of the valve. The sensor may be configured to detect a position of the indicator to determine the state of the valve. Such devices may include a housing configured to connect to a valve and a sensor supported on the housing.

In some embodiments, the device may include a memory device electrically connected to the sensor. As a non-limiting example, the memory device may be configured to store one or more reference points corresponding to the state of the valve, such as being fully opened, being fully closed, or partially opened. In other words, the memory device may store a position of the indicator corresponding to the state of the valve being fully opened and another position of the indicator corresponding to the state of the valve being fully closed. Such reference points may provide boundaries for determining the state of the valve relative to the state of the valve being fully opened or fully closed. As a non-limiting example, the position of the indicator relative to the sensor may correspond to the state of the valve being anywhere from about 0% to about 100% open or, alternatively, anywhere from about 0% to about 100% closed.

In additional embodiments, the device may include an electronic display electrically connected to the memory device. The electronic display may show the state of the valve relative to the valve being fully opened or fully closed. As a non-limiting example, the electronic display may include a number of independently activatable light-emitting diodes (LEDs) with certain LEDs illuminated in an on state and other LEDs in an off state, or alternatively, illuminated in another color representing an off state. The number of illuminated LEDs in the on state may correspond to the state of the valve relative to the valve being fully opened or fully closed.

Additive manufacturing techniques may be utilized to form one or more parts of the device, such as the housing that may have a complex geometry and/or may be customized based on the geometry of the valve to which the housing connects. As a non-limiting example, fused filament formation, direct metal laser sintering, electron beam melting, selective laser sintering, selective laser melting, binder jetting, powder bed fusion, or other 3D printing technique may be utilized to selectively fix particles of a material of the device in place and form covalent bonds among those particles to form the housing, and fixation and bonding may occur simultaneously in some embodiments.

Configurations of devices for measuring the state of a valve in accordance with embodiments of this disclosure may provide for non-intrusive monitoring of the state of a valve. Since valves used within industrial facilities may need to be recertified and/or recalibrated when installing or modifying internal flow measurement devices, using non-intrusive devices that monitor the state of the valve may reduce expenses and downtime associated with valve recertification, recalibration processes, and when checking the health or status of a valve (e.g., wear, presence of corrosion). Additionally, the device may be customized and retrofitted to specific valves to provide for proper sizing and accurate valve state measuring. Furthermore, the housing design and materials may be vibration resistant and may provide vibration damping or vibration isolation that may improve the accuracy of measuring the valve states and may prevent unnecessary maintenance or recalibration.

As used herein, the singular forms following “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

As used herein, “about” in reference to a numerical value for a particular parameter is inclusive of the numerical value and a degree of variance from the numerical value that one of ordinary skill in the art would understand is within acceptable tolerances for the particular parameter. For example, “about” in reference to a numerical value may include additional numerical values within a range of from 90.0 percent to 110.0 percent of the numerical value, such as within a range of from 95.0 percent to 105.0 percent of the numerical value, within a range of from 97.5 percent to 102.5 percent of the numerical value, within a range of from 99.0 percent to 101.0 percent of the numerical value, within a range of from 99.5 percent to 100.5 percent of the numerical value, or within a range of from 99.9 percent to 100.1 percent of the numerical value.

As used herein, “and/or” includes any and all combinations of one or more of the associated listed items.

As used herein, the terms “comprising,” “including,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, un-recited elements or method steps.

As used herein, the term “configured” refers to a size, shape, material composition, and arrangement of one or more of at least one structure and at least one apparatus facilitating operation of one or more of the structure and the apparatus in a predetermined way.

As used herein, any relational term, such as “first,” “second,” etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings, and does not connote or depend on any specific preference or order, except where the context clearly indicates otherwise.

As used herein, the term “may” with respect to a material, structure, feature, or method act indicates that such is contemplated for use in implementation of an embodiment of the disclosure, and such term is used in preference to the more restrictive term “is” so as to avoid any implication that other compatible materials, structures, features, and methods usable in combination therewith should or must be excluded.

The terms “memory” and “memory device,” as used herein, include microelectronic devices exhibiting, but not limited to, memory functionality, but exclude embodiments encompassing transitory signals. For example, a system on a chip (SoC) is encompassed in the meaning of memory device. By way of further non-limiting examples, memory devices may generally include packaged semiconductor devices having memory storage and read-write capability, such as, for example, hard drives, FLASH drives, NVME drives, memory cards, etc.

As used herein, reference to a feature being “on” an additional feature includes the features being in contact with one another, as well as directly or indirectly coupled to one another, connected to one another, attached to one another, or secured to one another.

As used herein, the term “state” in reference to a valve means and includes the position of a moveable fluid control member of the valve (e.g., valve stem, disk, plug, ball, gate, etc.) relative to the fluid passageway of the valve. For example, a valve state or a state of a valve may be fully opened (corresponding to the fluid control member being oriented to maximize the area of the fluid passageway of the valve), fully closed (corresponding to the fluid control member being oriented to prevent or minimize the area of the fluid passageway of the valve), or anywhere in between fully opened and fully closed.

As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0 percent met, at least 95.0 percent met, at least 99.0 percent met, at least 99.9 percent met, or even 100.0 percent met.

As used herein, the terms “vertical,” and “horizontal” are in reference to a major plane of a structure and are not necessarily defined by earth's gravitational field. With reference to the figures, a “horizontal” direction may be perpendicular to an indicated “Z” axis, and may be parallel to an indicated “X” axis and/or parallel to an indicated “Y” axis; and a “vertical” direction may be parallel to an indicated “Z” axis, may be perpendicular to an indicated “X” axis, and may be perpendicular to an indicated “Y” axis.

FIG. 1 is a partial cross-sectional perspective view of an embodiment of a system 100 for measuring the state of a valve 110. The system 100 may include the valve 110 and a device 120 for measuring the state of the valve 110. The device 120 may be configured to connect to the valve 110, as illustrated in FIG. 1 . The device 120 may be configured to measure the state of a rising-stem valve or any other valve type in which a valve stem 114 moves in a linear direction relative to a body of the valve and/or handle or hand-wheel of the valve.

In some embodiments, the valve 110 may include a valve body 112 in and on which other components of the valve are supported, and that may define an internal fluid passageway 113 to form a portion of a fluid path 115 through the valve 110. The valve 110 may include the valve stem 114 that may be movable relative to the valve body 112 and, optionally, a valve handle (e.g., hand-wheel 116) during opening and closing of the valve 110. The handle (e.g., hand-wheel 116) may be threadably connected to the valve stem 114, and the hand-wheel 116 may be configured to rotate relative to the valve body 112 and/or the valve stem 114. The hand-wheel 116 may additionally include a hub 117 and one or more spokes 118.

In operation, the hand-wheel 116 may be rotated to restrict (e.g., close) or expand (e.g., open) a portion of the internal fluid passageway 113 through the valve 110, and the hand-wheel 116 may be rotated in a single respective direction to fully open or fully close the valve 110. As a non-limiting example, the hand-wheel 116 of the valve 110 may be rotated in one direction (e.g., clockwise) to retract the valve stem 114 into the valve and restrict flow through, or close, the valve 110, or the hand-wheel 116 may be rotated in the opposite direction (e.g., counterclockwise) to advance the valve stem 114 out of the valve and increase flow through, or open, the valve 110. In some embodiments, the hand-wheel 116 may be intended primarily for manual operation. In other embodiments, the hand-wheel 116 may be intended solely for automatic operation or for some combination of automatic and manual operation.

FIG. 2 is an enlarged perspective view of the device 120 for measuring the state of the valve 110 illustrated in the system 100 of FIG. 1 . As illustrated in FIG. 2 , the device 120 for measuring the state of a valve may include a housing 130, a sensor 150 supported on the housing 130, and an indicator 160 that may be detectable by the sensor 150. In some embodiments, the device 120 may additionally include a memory device 170 electrically connected to the sensor 150, an electronic display 180 electrically connected to the memory device 170, and a power supply 190 electrically connected to one or more of the sensor 150, the memory device 170, and the electronic display 180. In some embodiments, the indicator 160 may be configured to move relative to the sensor 150 in response to movement of the valve stem 114 and, optionally, the valve hand-wheel 116 of the valve 110. For example, the indicator 160 may be affixed to the valve stem 114 of the valve 110 and, when affixed to the valve stem 114, the indicator 160 may move relative to the sensor 150 in response to movement of the valve stem 114 during opening and closing of the valve 110. Additionally, the sensor 150 may be configured to detect a position of the indicator 160 relative to the sensor 150 and to determine the state of the valve 110 in response to detection of the position of the indicator 160.

For simplicity, FIG. 2 depicts, and the following paragraphs describe the sensor 150 as being configured to be affixed to the housing 130, and the indicator 160 as being configured to be affixed to the valve stem 114. However, this disclosure is not so limited. The sensor 150 may be supported on or configured to be affixed to any component that is moveable with respect to a remainder of the valve 110 responsive to changes in the state of the valve, and the indicator 160 may be supported on or configured to be affixed to any other component with respect to which the valve stem 114 or other comparable moving component may move. For example, in some embodiments, the sensor 150 may be configured to be affixed to the valve stem 114, and the indicator 160 may be supported on the housing 130, such that the sensor 150 moves with the valve stem 114 relative to the indicator 160 during opening and closing of the valve 110. The sensor 150 may be configured to detect the position of the indicator 160 relative to the sensor 150 to determine the state of the valve 110 in response to detection of the position of the indicator 160. In other words, the sensor 150 may be configured to at least substantially continuously detect the position of the indicator 160 relative to the sensor 150 that corresponds to the state of the valve 110.

FIG. 3 is an enlarged perspective view of the housing 130 of the device 120 of FIG. 2 for measuring the state of the valve 110 illustrated in the system 100 of FIG. 1 . Referring now to FIG. 3 , the housing 130 may be a rigid structure and may include a central portion 132 that may optionally include access ports 134. The central portion 132 of the housing 130 may support and/or include surfaces on which the electronic display 180 may be secured. In some embodiments, the housing 130 may include a first, generally planar plate 136 on a distal end of the central portion 132 and a second, generally planar plate 138 located on a lateral side of the central portion 132. The housing may additionally include a base 140 at a proximal end, opposite the distal end, of the housing 130 that may be configured to be affixed to the valve 110 (FIG. 2 ). The housing 130 may include one or more connectors (e.g., one or more clips 142) extending from the base 140 along corresponding ones of the spokes 118 (FIG. 2 ) of the hand-wheel 116 (FIG. 2 ). Furthermore, the housing 130 may define a central cavity 146.

Returning to FIG. 2 , the housing 130 may support the sensor 150 or indicator 160, the memory device 170, the electronic display 180, and/or the power supply 190. The central portion 132 of the housing 130 may be generally aligned with, and at least partially surrounding, the valve stem 114. For example, a central geometrical axis of the central portion 132 may be aligned with an axis along which the valve stem 114 raises and lowers. The central portion 132 may be elongated, having a height that extends above the hand-wheel 116 greater than or equal to a maximum linear displacement achievable for the valve stem 114 relative to the hand-wheel 116. In some embodiments, the central portion 132 may generally be shaped as a prism (e.g., a right cylinder). The access ports 134 within the central portion 132 may enable visual and/or physical access between the interior and the exterior of the central portion 132 of the housing 130.

The first plate 136 or the second plate 138 (collectively, the “plates”) may support and/or include surfaces on which the memory device 170, the electronic display 180, and/or the power supply 190 may be secured. The sensor 150, the memory device 170, the electronic display 180, and/or the power supply 190 may be located inside, outside, partially inside, or partially outside of the housing 130. For example, the housing 130 may include covers to enclose any components supported on one or more of the plates 136, 138 that may be exposed to the environment. The plates 136, 138 supporting the sensor 150, the memory device 170, the electronic display 180, and/or the power supply 190 may facilitate accessibility to, and replacement of, the sensor 150, the memory device 170, the electronic display 180, and/or the power supply 190.

The base 140 of the housing 130 may be configured to be affixed to the valve 110. For example, the housing 130 may be configured to be affixed to the hand-wheel 116 such that the housing 130 and additional components thereon may remain stationary relative to, and may be movable with, the hand-wheel 116. In other words, the housing 130 may rotate with the hand-wheel 116 during opening and closing of the valve 110. In some embodiments, the housing 130 may be configured to connect to every spoke 118 of the hand-wheel 116. As a non-limiting example, the base 140 of the housing 130 may abut against the hub 117 of the hand-wheel 116, and the one or more connectors (e.g., the one or more clips 142) extending from the base 140 along corresponding ones of the spokes 118 of the hand-wheel 116. Each clip 142 may be configured to removably connect to a corresponding spoke 118. Although illustrated and described as clips 142, the one or more connectors may comprise any conventional connectors known in the art. Non-limiting examples of the connectors include straps, fasteners, chains, wires, hook-and-loop fasteners, magnets, etc.

The clips 142 may be formed from a material that is chemically nonreactive with the subject fluid or subject fluids intended to be used with the valve 110, and/or may be suitable for stable operation at temperatures, pressures, vibration, and exposure to other environmental conditions in the intended application. More specifically, the materials of the clips 142 may be formed into a suitable shape through additive manufacturing processes, and may have strength, density, natural frequency, reactivity, and other mechanical properties suitable for use in the intended application. As specific, non-limiting examples, the materials of the clips 142 may include metals, metal alloys, ceramics, polymers, and/or composite materials. The materials may include, for example, polyetherimide thermoplastics, chopped carbon fiber reinforced nylon, and continuous carbon fiber reinforced nylon. More specifically, non-limiting examples of polyetherimide thermoplastics may include Ultem™ 9085 commercially available from Stratasys of 7665 Commerce Way, Eden Prairie, Minn. 55344, chopped carbon fiber reinforced nylon may include Onyx, and continuous carbon fiber reinforced nylon may include a nylon composite base (e.g., Onyx, Onyx FR, Onyx ESD, Nylon) reinforced with continuous Carbon Fiber, each of which is commercially available from Markforged of 480 Pleasant St., Watertown, Mass. 02472. The materials of the clips 142 may provide resistance to temperature, corrosion, and/or vibration introduced by operating conditions of the system 100 (FIG. 1 ). Additionally, the clips 142 may be formed by conventional manufacturing techniques known in the art. As non-limiting examples, the clips 142 may be formed by subtractive manufacturing techniques, casting, molding, etc. In some embodiments, the clips 142 and/or a portion of the clips 142 may be formed unitarily with the housing 130. In additional embodiments, the clips 142 may be formed separately from and subsequently secured to the housing 130 by any conventional methods known in the art. As a non-limiting example, the clips 142 may be secured to the housing via straps, fasteners, chains, wires, hook-and-loop fasteners, magnets, etc.

In some embodiments, the housing 130 may be configured to removably connect to some, but not all, of the spokes 118 of the hand-wheel 116. As a non-limiting example, the housing 130 may include fewer clips 142 than spokes 118 of the hand-wheel 116. In some embodiments, the housing 130 may be configured to removably connect to additional components of the valve 110 that may be stationary relative to linear movement of the valve stem 114. For example, the housing 130 may be affixable to an exterior ring of the hand-wheel 116, the hub 117, or the valve body 112 (FIG. 1 ).

FIG. 4 is an enlarged perspective view illustrating the clips 142 of the housing 130 of FIG. 3 . Referring now to FIG. 4 , the clips 142 may include a first portion 143, a second portion 144, and a latch 145 to selectively secure the first portion 143 and second portion 144 together, and to selectively release the first portion 143 from the second portion 144. The second portion 144 may exhibit a channel shape with a ledge at distal ends of arms of the channel, and corresponding recesses or holes in the first portion 143 may facilitate a clip-in connection, which may enable quick and easy deployment as well as removal. In some embodiments, the clips 142 may be adjustable. For example, the first portion 143 of the clip 142 may include a number of recesses or holes 147 in ordered arrangements (e.g., lines) to adjust the second portion 144 that may be connected thereto. Although latch 145 is described and illustrated as being part of the second portion 144, the latch 145 may be a separate component and may be any latch or connector configured to connect the first portion 143 to the second portion 144. Additionally, the latch 145 may comprise any conventional connector known in the art and configured to adjoin two components. Non-limiting examples of connectors include straps, fasteners, adhesives (e.g., epoxy, polyurethane, polyimide, etc.), welding material, chains, wires, hook-and-loop fasteners, magnets, etc.

Returning to FIG. 2 , the first portion 143 may be located proximate the base 140 and abuttable against a portion of a given spoke 118, the second portion 144 may be positionable around a remainder of the spoke 118, and the latch 145 may selectively secure the first portion 143 and second portion 144 together around the spoke 118. In some embodiments, the first portion 143 may be separate from and affixable to the base 140, to facilitate easier reconfiguration of the housing 130 to accommodate different valve designs. In additional embodiments, the first portion 143 may be integral and monolithic with respect to the remainder of the central portion 132 of the housing 130.

The clips 142 being removably securable to the valve 110 may facilitate quick and easy installation of the device 120 and/or housing 130 on, and removal of the device 120 and/or housing 130 from, the valve 110. Additionally, removably securing or affixing the device 120 and/or housing 130 to the valve 110 may facilitate easy and quick removal from the valve 110 in case of an emergency. In some embodiments, the size and shape of each clip 142 may be customized and formed to correspond to the size and shape of the spoke 118 to which the clip 142 will connect. Customizing each clip 142 to the size and shape of a corresponding spoke 118 may facilitate a secure connection between the valve 110 and the device 120 and/or housing 130, and may reduce the likelihood of movement of the device 120 and/or housing 130 relative to the valve 110 during incidental contact (e.g., from a user adjusting the valve-wheel) and/or operating conditions such as vibration. As indicated above, in additional embodiments, the clips 142 may be adjustable. As a non-limiting example, the clips 142 may be adjustable to connect the device 120 and/or housing 130 to different designs of valves. As another non-limiting example, the clips 142 may be adjustable to loosen or tighten a connection between the valve 110 and the device 120 and/or housing 130 and to ensure firm and proper contact therebetween. Once connected, each clip 142 may remain connected until a threshold amount of separation force is applied to separate the first portion 143 from the second portion 144 of the clip 142. As non-limiting examples, the separation force may be from about 5 Newtons (N) to about 50 N, from about 7 N to about 40 N, or from about 10 N to about 25 N. In some embodiments, the separation force is about 15N.

The central cavity 146 defined by the central portion 132 of the housing 130 may be configured to receive the valve stem 114 and optionally the indicator 160 that may be connected to the valve stem 114. As a non-limiting example, the central cavity 146 may extend from the proximal end of the housing 130 through the central portion 132 to the distal end and may terminate proximate to the first plate 136 on the distal end of the housing 130. An interior surface (e.g., lateral side, top) of the central portion 132 may support and/or be a surface on which the sensor 150 or the indicator 160 is mounted. As illustrated in FIG. 2 , when the housing 130 is connected to the valve 110, the central cavity 146 may receive the portion of the valve stem 114 at the exterior of the valve 110 and the indicator 160 or sensor 150 that may be affixed to the valve stem 114. Additionally, access ports 134 may facilitate viewing and/or accessing the sensor 150 and/or the indicator 160 while the housing 130 is connected to the valve 110.

The housing 130 and features thereof may exhibit any suitable dimensions and any suitable shape for connecting to and/or receiving the valve 110. In some embodiments, the size and shape of the housing 130 may be customized based on the size and shape of the valve 110 and any components of the valve 110 to which the housing 130 may connect, and may also be based on dimensions of the valve stem 114, including a length of the valve stem 114 that protrudes from the valve 110 when the valve 110 is at a fully opened state (e.g., when the maximum amount of the valve stem 114 is external to the valve 110). As a non-limiting example and as illustrated in FIG. 2 , the central portion 132 of the housing 130 may exhibit a tubular shape.

Materials of the housing 130 may depend, at least in part, on the application for the device 120 and the valve 110. As a non-limiting example, the materials of the housing 130 may be chemically nonreactive with the subject fluid or subject fluids intended to be used with the valve 110, and/or may be suitable for stable operation at temperatures, pressures, vibration, and exposure to other environmental conditions in the intended application. More specifically, the materials of the housing 130 may be formed into a suitable shape through additive manufacturing processes, and may have strength, density, natural frequency, reactivity, and other mechanical properties suitable for use in the intended application. As specific, non-limiting examples, the materials of the housing 130 may include one or more metals, metal alloys, ceramics, polymers, and/or composite materials. The materials may include, for example, polyetherimide thermoplastics, chopped carbon fiber reinforced nylon, and continuous carbon fiber reinforced nylon. More specifically, non-limiting examples of polyetherimide thermoplastics may include Ultem™ 9085 commercially available from Stratasys of 7665 Commerce Way, Eden Prairie, Minn. 55344, chopped carbon fiber reinforced nylon may include Onyx, and continuous carbon fiber reinforced nylon may include a nylon composite base (e.g., Onyx, Onyx FR, Onyx ESD, Nylon) reinforced with continuous Carbon Fiber, each of which is commercially available from Markforged of 480 Pleasant St., Watertown, Mass. 02472. The materials of the housing 130 may provide resistance to temperature, corrosion, and/or vibration introduced by operating conditions of the system 100. The housing 130 may be a homogeneous material, a homogeneous composite of materials, or a heterogeneous composite of materials. As a non-limiting example, the density, material type, and/or relative concentrations of materials in the composite may be distributed in a gradient throughout the housing 130, such as varying through the thickness of the housing 130, varying from the distal end to the proximal end of the housing, and/or varying between the plates 136, 138 and the central portion 132 of the housing 130.

The housing 130 may be formed by additive manufacturing techniques in some embodiments. As non-limiting examples, fused filament formation, direct metal laser sintering, electron beam melting, selective laser sintering, selective laser melting, binder jetting, powder bed fusion, and other 3D printing techniques may also be utilized to selectively fix particles of the material of the housing 130 in place and form covalent bonds among those particles to form the housing 130.

Additively manufacturing the housing 130 and/or the clips 142 may enable manufacturing parts that are solid material, composites of materials, or shells of material with a hollow, partially filled, or fully filled interior. In some embodiments, the additive manufacturing process may include forming a shell and an interior infill within the shell. The amount of infill may vary from about 0% to about 100% infill. As non-limiting examples, the infill may be from about 10% infill to about 50% infill, from about 20% infill to about 40% infill (e.g., about 30% infill). Additionally, additive manufacturing processes herein may use an infill pattern (e.g., lines, zig-zag, grid, triangles, tri-hexagon, cubic, cubic subdivision, octet, quarter cubic, gyroid, concentric, cross, cross 3D, etc.) to achieve desired material properties. In additional embodiments, additive manufacturing may include forming part of the housing 130 and/or the clips 142 utilizing one material, and then forming the remainder of the housing 130 and/or the clips 142 utilizing one or more different materials. As a non-limiting example, the housing 130 may be formed by additively manufacturing a chopped carbon fiber shell with a 30% triangular pattern infill, and then substantially coating the chopped carbon fiber shell with continuous carbon fiber. The resulting housing 130 may exhibit about 95% chopped carbon fiber by weight and about 5% continuous carbon fiber by weight. Additively manufacturing the housing 130 may also facilitate forming custom housings and/or devices based on the dimensions of each individual valve 110 and may improve accuracy and reliability of detecting the valve states compared to conventional devices and may prevent unnecessary maintenance or recalibration. For example, dimensions of the valve 110, the valve stem 114, the hand-wheel 116, hub 117, and spokes 118 may be scanned and then the housing 130 may be additively manufactured with dimensions suitable for the housing 130 to connect to the valve 110.

The housing 130 and/or clips 142 may also be formed by conventional manufacturing techniques known in the art. As non-limiting examples, the housing 130 may be formed by subtractive manufacturing techniques, casting, molding, etc.

In some embodiments, the housing 130 may comprise a unitary structure formed with the plates 136, 138, the central portion 132, the base 140, and/or the clips 142 or a portion thereof. In additional embodiments, one or more features of the housing 130 (e.g., the plates 136, 138, the central portion 132, the base 140, and/or the clips 142) may be formed separately and then combined to form the housing 130.

In operation, the housing 130 may be connected to the spokes 118 of the hand-wheel 116 and the indicator 160 may be connected to an exposed end of the valve stem 114. The sensor 150 may be supported on the housing 130 and may be configured to detect a position of the indicator 160 to determine the state of the valve 110. As the hand-wheel 116 is rotated to change the state of (e.g., to open or close, partially open or close) the valve 110, the valve stem 114 and the indicator 160 attached thereto move into or out of the valve body 112 (FIG. 1 ) and relative to the sensor 150. In other words, the valve stem 114 and the indicator 160 move in a direction aligned with a longitudinal axis of the valve stem 114 (the “axial direction”) relative to the hand-wheel 116, and the sensor 150 on the housing 130. Additionally, the housing 130 and the sensor 150 on the housing 130 move rotationally relative to the valve stem 114 and the indicator 160 thereon. The sensor 150 detects the position of the indicator 160 in the axial direction, and the sensor 150 also detects any movement of the position of the indicator 160 in the axial direction as the state of the valve 110 changes to determine the state of the valve.

Continuing with reference to FIG. 2 , the sensor 150 may be positioned within and supported on and/or affixed to an interior surface of the housing 130. As non-limiting examples, the sensor 150 may be affixed to an interior surface of the central portion 132 of the housing 130, or the sensor 150 may be connected to an interior surface at the distal end of the housing 130 opposite the first plate 136. The sensor 150 may comprise any sensor configured to detect movement (e.g., linear, rotational) of the indicator 160 movable with the valve stem 114 and, optionally, the valve hand-wheel 116. As non-limiting examples, the sensor 150 may comprise a magneto-resistive sensor (e.g., a sensor that changes the value of its electrical resistance in response to an applied magnetic field), variable resistor (e.g., potentiometer), optical sensor, acoustic sensor, pull-out limit switch (e.g., cable pull switch), force sensor, tension sensor, etc. The sensor 150 may also be configured to at least substantially continuously detect the position of the indicator 160 on the valve stem 114 from an initial position to a subsequent position. As a non-limiting example, the sensor 150 may be configured to continuously detect the position of the indicator 160 from the fully closed state to the fully opened state of the valve 110, from the fully opened state to the fully closed state of the valve 110, and anywhere therebetween.

The indicator 160 may be configured to connect to the valve stem 114. As a non-limiting example, the indicator 160 may be removably affixable to the valve stem 114 utilizing magnetic attraction. Utilizing magnetic attraction to affix the indicator 160 may facilitate instantaneous removal of the indicator 160 in case of an emergency. Additionally, the indicator 160 may be removably securable to a portion of the valve stem 114 external to the valve 110. The indicator 160 may be configured to connect to the valve stem 114 in any way known in the art. As non-limiting examples, the indicator 160 may be configured to connect to the valve stem 114 using threads, adhesives (e.g., epoxy, polyurethane, polyimide, etc.), fasteners, magnets, etc. The indicator 160 may comprise any indicator 160 configured to move relative to the sensor 150 and configured to be detected by the sensor 150. As non-limiting examples, the indicator 160 may comprise a magnet, a light emitter (e.g., laser pointer), an acoustic wave emitter (e.g., acoustic transducer), a moving component of a pull-out limit switch, spring, extendable switch, etc.

As illustrated in FIG. 2 , and in some embodiments, the sensor 150 may comprise a magneto-resistive sensor and the indicator 160 may comprise a magnet. As a non-limiting example, the sensor 150 may comprise a linear potentiometer, such as a rectangular MagnetoPot commercially available from Spectra Symbol of 3101 W. 2100 S., Salt Lake City, Utah 84119, and the sensor 150 may extend from the distal end to the proximal end of the housing 130. When the indicator 160 and housing 130 are connected to the valve 110, the indicator 160 generates a magnetic field. The sensor 150 detects the position of the indicator 160 relative to the sensor 150 based on the magnitude of the magnetic field from the indicator 160. Movement of the indicator 160 may change the magnitude of the magnetic field detected by the sensor 150. Additionally, the resistance of the sensor 150 may vary corresponding to a change in the location of the indicator 160. The sensor 150 may at least substantially continuously detect the position of the indicator 160 on the valve stem 114 as the indicator 160 and the sensor 150 move relative to one another during opening and closing of the valve 110. As a non-limiting example, the sensor 150 may be configured to continuously detect the position of the indicator 160 from the fully closed state to the fully opened state of the valve 110, from the fully opened state to the fully closed state of the valve 110, and anywhere therebetween.

In additional embodiments, the sensor 150 may comprise an optical sensor and the indicator 160 may comprise a light source (e.g., laser) that may be oriented, for example, parallel to the longitudinal axis of the valve stem 114. For example, the sensor 150 may be secured to the housing 130 and arranged orthogonal to the length of the valve stem 114. When the housing 130 is connected to the valve 110 and the indicator 160 is connected to the valve stem 114, the indicator 160 may emit light perceivable (e.g., detectable) by the sensor 150. The sensor 150 may at least substantially continuously detect the intensity of light emitted from the indicator 160 and any variation in intensity of light emitted from the indicator 160 as the indicator 160 and the sensor 150 move relative to one another during opening and closing of the valve 110. As a non-limiting example, the sensor 150 may be configured to continuously detect the position of the indicator 160 from the fully closed state to the fully opened state of the valve 110, from the fully opened state to the fully closed state of the valve 110, and anywhere therebetween.

In further embodiments, the sensor 150 may comprise an acoustic sensor and the indicator 160 may comprise an acoustic transducer that may be oriented, for example, parallel to the longitudinal axis of the valve stem 114. For example, the sensor 150 may be positioned and connected to the interior surface on the distal end of the housing 130 opposite the first plate 136. When the housing 130 is connected to the valve 110 and the indicator 160 is connected to the valve stem 114, the indicator 160 may emit acoustic waves that are received by the sensor 150. The sensor 150 may at least substantially continuously detect the intensity of the acoustic waves emitted from the indicator 160 as the indicator 160 and the sensor 150 move relative to one another during opening and closing of the valve 110. As a non-limiting example, the sensor 150 may be configured to continuously detect the position of the indicator 160 from the fully closed state to the fully opened state of the valve 110, from the fully opened state to the fully closed state of the valve 110, and anywhere therebetween.

In additional embodiments, the sensor 150 may comprise a pull-out limit switch such as a cable pull switch and the indicator 160 may comprise the moving component (e.g., the cable) of the switch. For example, the sensor 150 may be positioned and connected to a rotatable plate on the interior surface on the distal end of the housing 130 opposite the first plate 136. The rotatable plate may reduce the propensity of (e.g., prevent) the pull-out limit switch to rotate relative to the valve stem 114 during opening and closing of the valve 110. When the housing 130 is connected to the valve 110, the indicator 160 may be secured to an end of the valve stem 114 to change (e.g., continuously) as the state of the valve 110 changes. For example, during opening and closing of the valve 110, the indicator 160 extends away from or retracts into the sensor 150 corresponding to the state of the valve. In other words, the sensor 150 may at least substantially continuously detect the position of the indicator 160 secured to the valve stem 114 as the indicator 160 and the sensor 150 move relative to one another during opening and closing of the valve 110. As a non-limiting example, the sensor 150 may be configured to continuously detect the position of the indicator 160 from the fully closed state to the fully opened state of the valve 110, from the fully opened state to the fully closed state of the valve 110, and anywhere therebetween.

Continuing with reference to FIG. 2 , the memory device 170 may include a processor, memory, an I/O interface, and a communication interface that may be communicatively coupled by way of a communication infrastructure. The processor includes hardware for executing instructions, such as the software configured as an operational program for at least substantially continuously monitoring the position of the indicator 160 relative to the sensor 150. In other words, the memory device 170 may update the position of the indicator 160 relative to the sensor 150 at least once per relevant subroutine cycle in a control software (e.g., at least once per minute, at least once per second, at least once per fraction of a second, etc.). The memory device 170 may be used for storing data, metadata, and programs for execution by the processor(s). The I/O interface allows a user to provide input to, receive output from, and otherwise transfer data to and receive data from the device 120. The communication interface may include hardware, software, or both. In any event, the communication interface may provide one or more interfaces for communication (such as, for example, packet-based communication) between the device 120 and one or more other computing devices or networks. As non-limiting examples, the memory device 170 may comprise a SimpleLink Wi-Fi CC3320SF microcontroller circuit board commercially available from Texas Instruments of 12500 TI Blvd. Dallas, Tex. 75243 and/or a WTR-100-900 commercially available from Cypress Envirosystems of 5883 Rue Ferrari, San Jose, Calif. 95138 to support 900 MHz communication.

In operation, the memory device 170 may be programmed to periodically or continuously gather data from the sensor 150 and may store reference points corresponding to the state of the valve 110 being fully opened, fully closed, and/or any state in between that of fully opened or fully closed. In other words, the memory device 170 may store the position of the valve stem 114 and indicator 160 thereon when the valve 110 is at a fully opened state, a fully closed state, or any state in between that of fully opened or fully closed. Additionally, a processor operably connected to the memory device 170 may be programmed to compare the current state of the valve 110 relative to the valve 110 being fully opened, fully closed, or any state in between that of fully opened or fully closed. For example, the processor may compare current data received from the sensor 150 and compare the data received to data received from the sensor 150 when the indicator 160 is at a position corresponding to the valve 110 being in a fully opened state, fully closed state, or any state in between that of fully opened or fully closed. Additionally, the memory device 170 may be electrically connected to the electronic display 180 and/or the power supply 190 and may be configured to send data and/or current to the electronic display 180 corresponding to the current state of the valve 110 relative to the valve 110 being fully opened, fully closed, or any other valve state between that of fully opened or fully closed. The memory device 170 may facilitate tracking the valve states of the valves 110 and may communicate the valve state of a single valve 110 to another communication system in order to remotely monitor the valve state of each valve 110 throughout a facility.

The electronic display 180 may be configured to show the current state of the valve 110 relative to the valve 110 being fully opened or fully closed. As non-limiting examples, the electronic display 180 may comprise an electroluminescent display (ELD), a liquid crystal display (LCD) (e.g., light-emitting diode (LED) backlit LCD, thin-film transistor (TFT) LCD), an LED display (e.g., organic light-emitting diode (OLED), active-matrix organic light-emitting diode (AMOLED), a plasma display (PDP), a quantum dot display (QLED), and/or cathode ray tubes). Additionally, the electronic display 180 may utilize light, color, text, images, etc., to present a visual representation of the state of the valve 110. For example, the electronic display 180 may use a green color to illustrate that the valve 110 is in a fully open state, may use a red color to illustrate that the valve 110 is in a fully closed state, may optionally use a yellow color to illustrate that the valve 110 is approximately halfway between the fully open and closed states, and may optionally show colors intermediate to red, yellow, and green to illustrate additional intermediate states of the valve 110. As another example, the display 180 may illuminate only certain LEDs in an array (e.g., in a line) generally corresponding to a percentage representing the state of the valve 110, where 0% corresponds to a fully closed state and 100% corresponds to a fully open state. As yet another example, the display 180 may depict in numbers and/or text a percentage representing the state of the valve 110, where 0% corresponds to a fully closed state and 100% corresponds to a fully open state. In some embodiments, the display 180 may utilize some combination or sub-combination of these, and other, techniques to visually represent the state of the valve 110.

In some embodiments, the electronic display 180 may comprise a number of independently activatable light-emitting diodes (LEDs). For example, each of the LEDs may include an independent switch that may be selectively activated by the memory device 170. As a non-limiting example, the electronic display 180 may include 10 LEDs. When the valve 110 is fully closed, the memory device 170 may prevent current from flowing to any of the LEDs and each of the LEDs may remain in an off state. When the valve 110 is fully opened, the memory device 170 may activate each of the LED switches and enable current to flow through and activate all 10 of the LEDs. Additionally, when the state of the valve is about 50% open, the memory device 170 may activate five of the 10 LEDs. Furthermore, the LEDs may be arranged into various configurations such as a segment display (e.g., seven-segment display, fourteen-segment display, or sixteen-segment display) and certain segments may be illuminated corresponding to the state of the valve 110. Additionally, the segment display may include one or more LED segment displays. As a non-limiting example, the electronic display 180 may include three seven-segment LED displays and may display a “000” when the valve is closed, a “100” when the valve is fully opened, and numbers “001” through “099” corresponding to intermediate positions relative to valve 110 being fully opened or fully closed.

In additional embodiments, the electronic display 180 may include a graphic user interface (GUI) display screen that is configured to electronically display a number followed by a percentage symbol and/or a letter or word to more precisely indicate the state of the valve 110. As a non-limiting example, the GUI screen may display 33% followed by a letter “o” or the word “open” to indicate the valve 110 is 33% open (e.g., a 33% change from the fully closed state). As another non-limiting example, the GUI screen may display 43% followed by a letter “c” or the word “closed” to indicate the valve is 43% closed (e.g., a 43% change from the fully opened state). Additionally, the level of resolution displayed on the GUI screen may be modified to include more or fewer decimal places in order to change the level of precision. As non-limiting examples, the GUI screen may display “33.1% open,” “33.17% open,” or 33.174% open. Accordingly, the electronic display 180 may facilitate quickly and easily determining the valve state of any given valve 110.

The power supply 190 may provide current to the memory device 170 and/or the electronic display 180. The power supply 190 may be or include any power supply system known in the art. As non-limiting examples, the power supply 190 may comprise one or more batteries, photovoltaic (e.g., solar) cells, etc. Additionally, the power supply 190 may comprise an alternating current source and may include a voltage regulator (e.g., relay) to convert alternating current to direct current. Although FIG. 2 illustrates the power supply 190 as connected to the second plate 138 of the housing 130, the power supply 190 may be connected to the first plate 136 of the housing 130. For example, connecting the power supply 190 to the first plate 136 may facilitate direct sunlight exposure onto the power supply 190 and may enable energy harvesting in embodiments in which the power supply 190 comprises photovoltaic cells.

FIG. 5 is a perspective view of another embodiment of a device 220 for measuring a state of a valve, in accordance with this disclosure. In FIG. 5 and the associated description, functionally similar features (e.g., structures, materials) are referred to with similar reference numerals incremented by 100. To avoid repetition, not all features shown in FIG. 5 are described in detail herein. Rather, unless described otherwise below, a feature in FIG. 5 designated by a reference numeral that is a 100 increment of the reference numeral of a previously described feature will be understood to be at least substantially similar to the previously described feature of FIG. 1 , FIG. 2 , or FIG. 3 .

The device 220 for measuring the state of a valve may include a housing 230, a sensor 250 that may be supported by the housing 230, and an indicator 260 that may be detectable by the sensor 250. In some embodiments, the device 220 may additionally include a memory device 270 electrically connected to the sensor 250, an electronic display 280 electrically connected to the memory device 270, and a power supply 290 electrically connected to one or more of the sensor 250, the memory device 270, and the electronic display 280. For example, the memory device 270, the electronic display 280, and/or the power supply 290 may be supported on the housing 230. In some embodiments, the indicator 260 may be configured to connect to valve stem 214 that may extend from and retract into a hub 217 of a hand-wheel 216 of valve 210. When the indicator 260 is connected to the valve stem 214, the indicator 260 may move relative to the sensor 250 in response to movement of the valve stem 214 during opening and closing of the valve 210. Additionally, the sensor 250 may be configured to detect a position of the indicator 260 to determine a state of the valve 210.

The housing 230 may include a central portion 232, a plate 236 on a distal end of the housing 230 and a base 240 on a proximal end, opposite the distal end. As illustrated in FIG. 5 , the central portion 232 may support and/or include surfaces on which the electronic display 280 may be secured. The plate 236 may support the memory device 270, the power supply 290, and/or the electronic display 280. The base 240 of the housing may be configured to connect to the valve 210. As a non-limiting example, the base 240 of the housing 230 may be configured to connect to the valve body 212, as illustrated in FIG. 5 . The base 240 may include two linear feet 241 that may be spaced apart by about the width (e.g., diameter) of a portion of the valve body 212, and the base 240 may slidably connect to the valve body 212. The linear feet 241 may be adjustable to narrow the spacing between the feet and/or secure the base 240 to the valve body 212. Further, the base 240 may include a connector to span between the two linear feet 241 so the base 240 substantially surrounds the valve body 212 to secure the housing 230 to the valve 210 utilizing a clamping force.

The housing 230 may be adjustable. For example, the plate 236 and the base 240 may be horizontally adjustable (e.g., in the X-direction, and/or Y-direction) relative to the central portion 232 in order to align the base 240 to connect to the valve 210 and to align the plate 236 with the valve stem 214. Additionally, the central portion may be vertically (e.g., in the Z-direction) adjustable to increase or decrease a distance between the plate 236 and the base 240 and/or to position the sensor 250 in close proximity to the indicator 260. The base 240 of the housing 230 may be configured to connect to the valve 210 at any suitable location.

In operation, the housing 230 may be connected to the valve body 212 and the indicator 260 may be connected to an end of the valve stem 214. The sensor 250 may be supported on the housing 230 and may be configured to detect a position of the indicator 260 to determine a state of the valve stem 214 and corresponding position of the valve 210. As the hand-wheel 216 is rotated to change the state of (e.g., to open or close) the valve 210, the hand-wheel 216 and the indicator 260 thereon rotates with hand-wheel 216 relative to the sensor 250. The sensor 250 detects a position of the indicator 260 relative to a direction parallel to a longitudinal axis of the valve stem 214, and the sensor 250 may also detect changes in the position of the indicator 260, in substantially the same manner as previously discussed with reference to FIG. 2 .

In additional embodiments, the device 220 may be configured to measure a state of a different type of valve (e.g., a rising-handle valve). For example, the indicator 260 may be configured to connect to the hand-wheel 216 at the hub 217 that may be secured to and movable with the valve stem 214. When connected to the hub 217, the indicator 260 may move relative to the sensor 250 in response to movement of the valve stem 214 during opening and closing of the valve 210. Additionally, the sensor 250 may be configured to detect a position of the indicator 260 to determine a state of the valve 210.

In operation, the housing 230 may be connected to the valve body 212 and the indicator 260 may be connected to the hub 217 moveable with the valve stem 214. The sensor 250 may be supported on the housing 230 and may be configured to detect a position of the indicator 260 to determine a position of the hub 217 and/or valve stem 214 to determine the state of the valve 210. As the hand-wheel 216 is rotated to change the position of the hub 217 (e.g., to open or close, to partially open or partially close the valve 210), the hand-wheel 216 and the indicator 260 thereon moves (e.g., in a direction aligned with a longitudinal axis of the valve stem) and relative to the sensor 250. The sensor 250 detects a position of the indicator 260 relative to a direction parallel to a longitudinal axis of the valve stem 214, and the sensor 250 may also detect changes in the position of the indicator 260, in substantially the same manner as previously discussed with reference to FIG. 2 .

FIG. 6 is a flow chart showing an illustrative method for measuring a valve state in accordance with embodiments of this disclosure. The method 600 may involve, for example, determining an initial valve state of a valve at act 602. More specifically, determining an initial state of the valve may involve, for example, comparing an initial position of the indicator to an indicator position corresponding to at least one of a fully opened state reference position or a fully closed state reference position.

A change in position of an indicator movable with a valve stem of the valve may be detected, relative to the initial valve state, in response to movement of the valve stem, as indicated at act 604.

A subsequent valve state may be determined based on a change in position of the indicator by detecting a position of the indicator utilizing a sensor supported on a housing affixed to a handle of the valve, as indicated at act 606. For example, a subsequent valve state may be determined by detecting a linear distance from an initial indicator position to subsequent indicator position. In additional embodiments, the valve state may be displayed by utilizing an electronic display.

FIG. 7 is a flow chart showing an illustrative method for additively manufacturing a housing (e.g., the housing 130, 230) of a device for measuring a valve state, in accordance with embodiments of this disclosure. The method 700 may involve, for example, determining at least some dimensions of a valve handle and a valve stem of a valve, as indicated at act 702.

A material may be sequentially placed at targeted locations based on the at least some dimensions of the valve stem, as indicated at act 704.

The material may be affixed in place to form a housing configured to receive the valve stem at least partially therein, as indicated at act 706.

Additional material may be sequentially placed at target locations based on the at least some dimensions of the valve handle, as indicated at act 708.

The additional material may be affixed in place to form one or more clips secured to the housing and configured to removably connect to the valve handle, as indicated at act 710.

Embodiments of devices for measuring the state of a valve in accordance with this disclosure may provide for non-intrusive, real-time monitoring of the state of a valve that may reduce expenses and downtime associated with valve recertification and recalibration. Additionally, the device may be customized and retrofitted to specific valves to provide for proper sizing and connections for accurate valve state monitoring. For example, dimensions of a valve handle, valve handle spokes, a hub of the valve handle, and dimensions of a valve stem (e.g., length, diameter, etc.) may be measured to provide input dimensions for a housing of the device that may be subsequently formed to fit the valve. The housing and connectors configured to secure the housing to the valve may be additively manufactured in a unitary structure so there are no moving parts that need to be adjusted. When the device is secured to the valve, a user may be able to quickly remove the entire device from the valve in case of an emergency. Furthermore, the housing design and materials may be resilient and adaptable to operating conditions such as temperature, chemical decomposition, and vibration, which may improve the accuracy of measuring the valve state compared to conventional devices and may prevent unnecessary maintenance or recalibration. Embodiments of devices for measuring the state of the valve stem or valve handle in accordance with this disclosure may also provide a visual indication of the state of the valve to which each device is connected.

The embodiments of the disclosure described above and illustrated in the accompanying drawings do not limit the scope of the disclosure, which is encompassed by the scope of the appended claims and their legal equivalents. Any equivalent embodiments are within the scope of this disclosure. Indeed, various modifications of the disclosure, in addition to those shown and described herein, such as alternative useful combinations of the elements described, will become apparent to those skilled in the art from the description. Such modifications and embodiments also fall within the scope of the appended claims and equivalents. 

What is claimed is:
 1. A device for measuring a state of a valve, the device comprising: a housing separate from the valve and configured to be affixed and supported by to a handle of the valve via one or more connectors; a sensor supported on the housing; and an indicator detectable by the sensor, wherein the indicator is configured to move along the housing relative to the sensor in response to movement of a valve stem of the valve during opening and closing of the valve, wherein the sensor is configured to detect a position of the indicator to determine a state of the valve.
 2. The device of claim 1, further comprising a memory device electrically connected to the sensor, the memory device configured to store a first reference point corresponding to a first position of the indicator when the state of the valve is fully opened and a second reference point corresponding to a second position of the indicator when the state of the valve is fully closed.
 3. The device of claim 2, wherein the memory device is configured to store an initial position of the indicator corresponding to an initial state of the valve.
 4. The device of claim 3, further comprising an electronic display electrically connected to the memory device, wherein the electronic display is configured to show the initial state of the valve relative to the state of the valve being fully opened and fully closed.
 5. The device of claim 4, wherein the sensor is configured to at least substantially continuously detect the position of the indicator, and wherein the electronic display is configured to at least substantially continuously display the state of the valve relative to the state of the valve being fully opened and fully closed.
 6. The device of claim 4, wherein the electronic display comprises a number of independently activatable light-emitting diodes (LEDs).
 7. The device of claim 6, wherein each LED has a different color corresponding to a respective state of the valve.
 8. The device of claim 1, wherein the indicator comprises a magnet removably securable to the valve stem of the valve and the sensor comprises a magneto-resistive sensor secured to the housing and arranged parallel to a length of the valve stem.
 9. The device of claim 1, wherein the indicator comprises a laser oriented parallel to a longitudinal axis of the valve stem of a rising-stem valve and the sensor comprises an optical sensor secured to the housing and arranged orthogonal to a length of the valve stem, wherein the laser is configured to emit light directly onto the optical sensor.
 10. The device of claim 1, wherein the housing includes a top plate and a base, wherein the sensor extends between the top plate and the base in a direction of an axis of the valve stem of the valve, and the indicator is positioned in close proximity to the sensor between the top plate and the base.
 11. The device of claim 1, wherein the indicator is affixable to the valve stem utilizing fasteners, adhesives, or magnetic attraction.
 12. The device of claim 1, wherein the one or more connectors comprises a clip configured to connect to a spoke of a hand-wheel.
 13. A system for measuring a state of a valve, the system comprising: a valve comprising: a valve body; a handle operable to open and close the valve; and a valve stem movable relative to the valve body during opening and closing of the valve; and a sensor device comprising: a housing separate from the valve, the valve affixed to and supported by and the handle of the valve via one or more connectors; a sensor supported on one of the housing or the valve stem; and an indicator detectable by the sensor and supported on the other of the housing or the valve stem, wherein the indicator is configured to move relative to the sensor in response to movement of the valve stem during opening and closing of the valve, wherein the sensor is configured to detect a position of the indicator to determine a state of the valve.
 14. The system of claim 13, wherein the housing includes a top plate and a base, and wherein each of the sensor and the indicator is positioned opposite the valve body relative to the handle between the top plate and the base.
 15. The system of claim 13, wherein the sensor device is detachable from the valve.
 16. The system of claim 13, wherein the valve comprises a rising-stem valve, and wherein the one or more connectors comprises a clip removably connected to at least one spoke of a hand-wheel of the rising-stem valve.
 17. The system of claim 16, wherein the clip is adjustable.
 18. The system of claim 16, wherein the housing is formed unitarily with at least a portion of the clip.
 19. The system of claim 13, wherein the indicator comprises an acoustic sensor oriented parallel to a longitudinal axis of the valve stem of a rising-stem valve and the sensor comprises an acoustic transducer secured to the housing and arranged orthogonal to a length of the valve stem, wherein the acoustic transducer is configured to emit acoustic waves directly onto the acoustic sensor.
 20. A method of forming a device housing for a valve, the method comprising: determining at least some dimensions of a valve handle and a valve stem of a valve; sequentially placing a material at targeted locations based on the at least some dimensions of the valve stem; affixing the material in place to form a housing configured to receive the valve stem at least partially therein; sequentially placing additional material at targeted locations based on the at least some dimensions of the valve handle; and affixing the additional material in place to form one or more connectors secured to the housing and configured to removably connect the housing to the valve handle. 